Dairy animal milking preparation system and methods

ABSTRACT

The present invention relates to preparing dairy animal teats for being milked, and more particularly to teat preparation, rinsing, and milking that all take place in a milking machine teat cup liner. Such a method includes: applying a teat sanitizer to the teat; injecting air into the liner to force the teat sanitizer toward a waste milk line connected to the liner; pulsating the liner at a first pulsation rate; drawing a rinsing milk from the teat; directing the teat sanitizer, the air, and the rinsing fluid to the waste milk line; pulsating the liner at a second pulsation rate to draw additional milk from the teat; and directing the additional milk to a good milk line.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No.14/572,533 filed Dec. 16, 2014, which is a continuation of abandonedU.S. application Ser. No. 13/281,171 filed Oct. 25, 2011, which is acontinuation in part of U.S. application Ser. No. 12/932,276 filed Feb.22, 2011, which claims the benefit of Provisional Application No.61/338,630 filed Feb. 22, 2010, the disclosures of which areincorporated by reference herein.

FIELD AND BACKGROUND OF THE INVENTION

The present invention relates to preparing dairy animal teats for beingmilked, and more particularly to teat preparation, rinsing, and milkingthat all take place in a milking machine teat cup liner.

Other aspects of the invention include an apparatus and methods formilking dairy animals and collecting milk, and more particularly to adairy harvesting facility with apparatus and methods for protecting milkcollecting lines and systems from various types of cleaning fluids andcontaminated milk.

Dairy animal teat preparation is usually necessary before milking toprevent dirt and debris from entering milk lines and contaminating milk.Teat preparation also stimulates teats to release oxytocin and to “letdown” milk in advance of milking. Stimulation increases milk pressure inthe udder so that milking is efficient and reasonably fast.

Teat preparation can also include a step of applying a teat sanitizer toa teat and rinsing the teat and liner to minimize the possibility ofteat sanitizer entering the milk line. Teat preparation in prior systemstakes place before a milker teat cup and liner are placed on the teat.To expedite milking in robotic milking machines, for example, teatpreparation can take place in a teat cup liner, but teat sanitizers anddirt must be rinsed from the liner before milking so as not tocontaminate milk.

Once teat stimulation begins there can be a release of “foremilk” thatis not very high in fat and contains a higher percentage of water. “Goodmilk” usually comes after the foremilk, and it flows out at variousrates depending on milk pressure in the udder. Also, milk does not flowcontinuously during milking, it flows in intermittent “slugs” as aresult of a pulsating pressure being applied by the teat cup liner.

Pulsation in the milking process is applied by alternating vacuum andatmospheric pressure in a chamber that is between a teat cup and theteat cup liner. A constant vacuum is applied inside the liner from themilk lines to draw milk from the teat through the hoses and other milkcollecting components. This constant vacuum also secures the teat cup onthe teat. The pulsation on the outside of the liner opposes the constantvacuum on the inside of the liner and results in the liner alternatingbetween applying pressure and applying little or no pressure on a teat.

Normal pulsation rates are set to match dairy animal physiology so thatmilk is drawn from a teat at a reasonable rate and replenished by milkbeing let down from the udder while maintaining cow comfort. Applyingpulsation at a relatively high rate causes the liner to apply pressureso quickly that little or no milk is let down from the udder betweenpulses. Thus, faster pulsation does not always result in faster milking.

The preparation process is further complicated because not all dairyanimals are at the same stage of milking readiness when they enter amilking stall. Animals are sometimes referred to as “easy-let-down cows”or “slow-let-down cows.” As the names suggest, easy-let-down cows entera milking stall with relatively high milk pressure in their udders, sothat once the foremilk is stripped, they are ready to be milked at astandard pulsation rate. On the other hand, slow-let-down cows haverelatively low milk pressure in their udders and they requirestimulation for up to 90 seconds, but even longer times may bedesirable. The stimulation causes the cow to generate or releaseoxytocin that in turn causes the milk to be “let down” toward the teats,raise milk pressure, and facilitate milking.

Also, an individual cow can be an easy-let-down cow at some times, and aslow-let-down cow at others. Lactation cycles, milking frequency,ambient conditions, and animal health are a few of the factors affectingthe readiness of a cow to be milked.

Teat preparation, therefore, is not a simple matter because cleaning,stimulation, rinsing, and stripping foremilk must all be accomplished ina short time and without risk of contaminating the milk lines to acentral storage tank while accommodating the conditions of individualcows.

Of course, cows have four teats and each teat (and udder quarter) canrespond somewhat independently of the others. All of the factorsdescribed above for easy-let-down cows versus slow-let-down cows canapply to each individual teat.

Further complications result when the cows are to be milked by a roboticmilking machine that automatically attaches (or attempts to attach) teatcups with their teat cup liners to an animal's teats. The teat cups arenot all attached simultaneously. They are usually attached one at atime, and preferably in short succession. Nonetheless, sometimesattachment attempts fail and must be retried automatically or with theaid of a dairy operator. Preparing all four teats to provide optimummilking is, thus, even further complicated given the staggered starts onthe teats.

The process is further complicated when it is all done after a dairyanimal's teat is attached to a milking machine teat cup and teat cupliner because sanitizers, rinses, and foremilk must not be allowed intothe dairy's milk lines.

Thus, there is a need for an automated preparation process or protocolfor a teat that is already in the teat cup liner with a reduced risk ofcontaminating the dairy milk lines.

In dairy milking systems, sanitary conditions must be maintained to theextent possible. Dirt can enter a dairy milk system through the teat cupand liner that are attached to an animal to extract milk. Vacuum is usedto milk the animal and draw milk into the hoses, lines and storage tanksystem in the dairy. Any dirt on the animal's teats can be drawn intothe system by this vacuum.

To minimize dirt in the dairy milking system, a dairy animal is preparedfor milking by an operator who typically washes or otherwise cleans theanimal's teats. Cleaning before milking minimizes the chance that dirtand debris will enter the milk system in the dairy while the animal ismilked, and also permits the operator to extract (“strip”) foremilk fromthe teats and massage the teats so they are better prepared for milking.

In dairies time is of the essence, so preparing the animals must be donequickly and thoroughly. At least one and sometimes two or threeoperators will be stationed at a milking parlor entrance to prepare andthen attach a milker unit to each animal.

Milker units have teat cups and teat cup liners that cooperate withvacuum in the milking system to milk the cows. A teat cup and linerreceives nearly all of the teat so any dirt on the teat could make itinto the teat cup and liner and then the milk system. Logically, dirtshould be removed before a teat is inserted into an inflation.

Between preparation of the animal for milking and attachment of themilker unit, it is possible that more dirt and debris could attach tothe animal's teats because of the nature of a dairy environment. So evenwith good and efficient operators, some dirt can still make it into themilking system.

To reduce labor and improve cleaning and efficiency, there are automatedteat cleaning systems that include teat cups similar in appearance toteat cups on a milker unit. Teat cups on a cleaning system wet the teatswith water and/or sanitizer, and they may include brushes to aid incleaning. Some even include pulsators that spray pulses of liquid towardthe teat. After cleaning, the cleaning system cups are removed and thena milker unit is attached to the animal for milking. Attaching twoseparate units to the animals with the teats exposed for a briefinterval in between, wastes valuable time and risks the teats becomingdirty again.

Another automated preparation system is combined with a milker unit sothat only one machine is attached to an animal for preparation andmilking. This saves time and ensures that the teats are not exposed todirt between preparation and milking. This system is efficient andeffective, but attaching a preparation system to a milking system may bea possible source of contamination because vacuum in the milking systemcould draw sanitizer, water or dirt from the cleaning system into themilking system.

Sanitizer and water used to clean teats must not be allowed to mix withmilk that will be consumed by humans or calves. Moreover, dairy pipelinewashing fluids and contaminated milk must not be allowed to enter milklines that transport milk to centralized chillers and storage tanksunless the milk lines themselves are to be cleaned.

In apparatus that both clean and milk, a four-way valve separates thewash lines and the milk lines in an effort to prevent milk and milk linecontamination. To further avoid contamination, a small amount of milkfrom the start of the milking process is diverted to a waste line toensure that residual washing fluids are carried away before usable milkis directed to the dairy's milk lines.

Nonetheless, a four-way valve can be insufficient to prevent cleaningfluids and contaminated milk from entering the dairy milk collectingsystem because vacuum in the milk lines (used to draw milk to a centralstorage location) results in the milk line having a different pressurethan the wash lines, and the wash lines are subjected to variouspressures before and after a wash cycle. Differential pressure andvacuum applied on opposite sides of a four-way valve are likely to causeseepage and leaking of milk and/or cleaning fluids past seals in thefour-way valve. Thus, the competing pressures in the various linesattached to the four-way valve could eventually cause valve failure andmilk line contamination to some degree.

This problem is well known in dairies that use clean-in-place (“CIP”)wash systems. CIP wash systems are connected to dairy milk collectinglines, which are at a position downstream from milker units and theirrespective long milk tubes. Milk flows from the milk collecting lines toa dairy's central milk storage system.

To avoid contamination through valves as described above, the milk linesand CIP lines are required by FDA Regulations to be separated by a pairof spaced apart valves with a bleed vent in between the two valves. Thebleed vent is open to atmospheric pressure so that pressure or vacuum inone line bleeds off without affecting the other line. This arrangementof valves and a vent is known as a “block-bleed-block” system.

When two valves are separated by a vent or “bleed” to atmosphere, thereis no possibility that milk or washing fluids can be drawn past eithervalve because vacuum in the milk line is dissipated by the bleed ventand the two valves are physically separated, so there is no fluidcommunication between the two. In operation, a block-bleed-block systemhas one of the valves open to expose a desired pipe line to the milkerunit, while the other valve is closed. Even if one valve fails, thespaced apart and vented relationship between the valves prevents crosscontamination. Other teat dip applicators have been disclosed thatinclude block-bleed-block features.

The block-bleed-block arrangement is not new to the dairy industry, butimplementing a block-bleed-block system is not always possible,convenient or practical. In CIP systems, the valves and bleed vent aredisposed in an easily accessible area and can be of any convenient sizebecause they are positioned well away from the milker units and otherworking components of the milking system. Expense for building andmaintaining these systems can be prohibitive, so when space does notpermit a block-bleed-block arrangement, some milking systems aredesigned to segregate wash and milk lines in other ways.

One such alternative way to isolate milk and cleaning lines from oneanother is to manually disconnect a wash line and/or a milk line whennot in use. Such a procedure is effective, but obviously requires anoperator to be present between milking and washing operations. Inrobotic systems, the intent is to reduce operator involvement in allphases of the washing and milking operations. Requiring an operator tobe involved is further complicated in robotic systems because milkingmachines are washed only when necessary, and not on a regular basis thatwould be conducive to operator scheduling. Involving an operator wouldlikely slow down the milking process for the dairy as a whole, and wouldat least partially defeat the point of a robotic milking system.

Therefore, it is desirable to have an automated or robotic milkingsystem that does not risk contamination of milk and milk lines orrequire operator involvement, and is practical to build, install, andmaintain.

SUMMARY OF THE INVENTION

Among other things, the present invention properly prepares a dairyanimal teat for milking while the teat is disposed in a milking machineteat cup liner, and protects dairy milk lines from contamination.

The invention can include a method having the steps of sealing off theliner from a good milk line; applying pulsation at a first frequency;applying a teat sanitizer to the teat while the teat is in a teat cupliner; allowing sanitizer to remain on the teat for a predeterminedperiod of time; forcing air into the liner to at least partially dry theteat and force any remaining sanitizer toward a “bad” or waste milkline; drawing a rinsing milk from the teat (and/or supplying a rinsingfluid to rinse sanitizer toward a waste milk line); changing thepulsation rate to a second frequency; directing the rinsing milk and/orfluid to the waste milk line; sensing rinsing milk and/or fluid beingdirected to a waste line; closing the waste milk line and opening thegood milk line; and drawing good milk into the good milk line.

Preferably, a double block valve arrangement with a vent between theblocks isolates the good milk line during teat preparation. Teatsanitizer can be applied to the entire teat surface through a passage inthe milking liner. The sanitizer is preferably allowed to remain on theteat for a period of time that corresponds to optimum “kill times” forparticular sanitizers. Air is forced through the passage or anotheropening to spread sanitizer over the teat and to purge at least some ofthe excess sanitizer out of the liner. Preferably, the teat sanitizersupply line is completely isolated from the milk line by a double blockvalve or valves. In such arrangements, the sealed valves or “blocks” areseparated by a vent or “bleed” to reduce the chance of sanitizer leakingthrough a seal.

During preparation, the teat cup liner can be vented with air allowed inthrough the teat sanitizer valve. In this way, vented air can continueto be admitted to help dry the teat during the preparation process andpossibly, even during milking.

In one embodiment, some “rinsing” milk is drawn from the teat and usedto rinse teat sanitizer from the teat cup liner and into a waste milkline. In another embodiment, a rinsing fluid is introduced to the linerand/or a milk tube downstream from the teat cup and liner. Then, valvesisolating the teat cup liner from the good milk line and the waste milkline are switched and good milk is allowed to flow to the good milkline.

One benefit of preparing and milking teats in a single teat cup is thatdirt on the underside of the cow is not introduced into the milkcollecting system following a teat sanitizing process that takes placebefore the milking teat cup and liner are attached to the dairy animal.

When the invention is being used in a robotic milking machine or otherautomated milking machine, a cow is identified by a controller as beingacceptable for milking, a robot travels and removes a milking “cluster”(teat cups with corresponding liners) from a cleaning or “docking”station. The milking cluster is moved under the cow, the teats arelocated using any suitable means, and the teat cups are attached toteats. If one or more teats are not automatically located in apredetermined period of time, vacuum is shut off and the teat locatingprocess is attempted again.

Vacuum with pulsation is applied to the liner when searching for a teatso that when a teat is located, vacuum attaches the cup and liner to theteat and then remains on throughout preparation process and milking. Asdescribed below, pulsation can be varied during the preparation process.

The controller can be accessed to determine an individual animal'smilking and health record and the record can be displayed on a screen.Also, the individual animal's history of responses to the preparationprocess can be used to determine appropriate pulsation rates anddurations during the preparation process.

When the teat location process begins, valves to and from the teat cupliner are positioned to divert all fluid flow to a waste milk or “badmilk” line of any suitable type that leads to any suitable receptaclefor disposal or further analysis. The “first” pulsation rate used at thestart of the preparation process is preferably not the same as the“second” pulsation rate used during normal milking. Preferably, thefirst pulsation rate is significantly higher than a “normal” milkingpulsation rate so that the liner applies longer contact pressure againstthe teat. This higher pulsation rate can draw some of the foremilk fromthe teat, but preferably it only stimulates the teat to increase milkpressure in the udder.

Also, this first pulsation rate can be at the same or lower pulsationrate, can be used for any desired time or any variable period of time.Preferably, the first pulsation rate is relatively high and lasts up toabout 90 seconds. Duration periods used herein are not intended to beexact, because different factors affect when the pulsation actuallybegins or stops acting on the teat. Approximate pulsation duration ratesindicated throughout this specification are therefore appropriate.

In the present invention, some milk is drawn from the teat into theliner and into a first milk line joined to a downstream end of theliner. The first milk line leads to the waste milk line and to the goodmilk line. Rinsing milk or other rinsing fluid is directed to help rinsesanitizer and dirt from the liner. The milk that performs the rinsingprocess is referred to herein as “rinsing milk.” Nonetheless, some “goodmilk” will likely be drawn into the waste milk line to adequately rinsesanitizer from the liner, the rinsing milk is not necessarily wastemilk.

Indeed, it is desirable to avoid using good milk to rinse sanitizer fromthe teat liner. One method for doing so, is to introduce rinsing fluidand/or air into the liner to rinse sanitizer and thereby avoid usinggood milk for this purpose. Preferably, the rinsing fluid is introducedto the first milk tube downstream from the teat to prevent contaminationof the teat and minimize wasting good milk.

The terms “rinsing milk” and “rinsing fluid” are used interchangeablyherein and those terms as well as combinations thereof are sometimesreferred generically “rinsing fluid.” Rinsing milk can include theforemilk, and/or good milk, and it can also include sanitizing fluid,air or any other fluid or debris being rinsed from the liner. Therinsing milk used to rinse the liner preferably includes a minimalamount of good milk because sending good milk to the waste milk linereduces milk yields.

The rinsing fluid can be monitored in the milk cup liner, first milkline, waste milk line, waste milk receptacle, or any other suitablelocation. Preferably, there are one or more sensors in the first milkline to determine one or more factors, such as: whether any rinsing milkand/or rinsing fluid is flowing, the frequency of any “slugs” of rinsingmilk passing into the waste milk line; or the mass, volume, flow rate,conductivity or any other property of rinsing milk that provides usefuldata regarding the preparation process and completeness of rinsing.Other types of data can also be collected that relate to cow health orother characteristics, if desired.

Each rinsing fluid sensor sends corresponding data to the controller todetermine whether adequate rinsing has occurred. The adequacy of rinsingdepends on a number of factors and can be accounted for in thecontroller using a suitable empirical formula or other factor such as apredetermined length of time of rinsing milk flow. Thus, it is possible,but not necessary to directly determine the quality of the rinsing milkbecause a volume of slug frequency generally corresponds to the amountof rinsing fluid that is known or predicted to be adequate for rinsing.

After rinsing, the waste milk line should be closed and the good milkline should be opened. The liner can be “vented” from the sanitizervalve as described above. Data from the rinsing fluid sensor might alsobe used to transition pulsation from the first pulsation rate to thesecond pulsation rate.

It is also possible to use a good milk line sensor to determine whethermilk flowing in the good milk line is relatively free of sanitizer andrinsing fluid. This is not necessary, but can be useful if desired.

In any event, the transition from sending rinsing fluid to the wastemilk line to drawing additional milk into the good milk line can bedetermined by the controller using predetermined criteria about therinsing fluid, the length of time rinsing fluid is flowing into thewaste milk line, arbitrary time standards or any other factor thatensures adequate rinsing while minimizing waste of good milk.

As stated above, two pulsation rates are preferably used. The secondpulsation rate is preferably a normal milking pulsation rate, but otherrates can be used in the invention. The transition from the firstpulsation rate to the second pulsation rate does not necessarilycorrespond to the switch from draining rinsing fluid to collecting goodmilk. For example, a slow-let-down cow might not give any significantamount of foremilk or good milk while the first pulsation rate is beingapplied.

In such a case, milk might not be drawn from the teat until the secondpulsation rate is started. The second pulsation rate is preferably a“normal” rate for milking cows and it may be required to begin drawing asufficient quantity or flow rate of rinsing milk. As stated above, therinsing milk and/or rinsing fluid is necessary to remove as much of theteat sanitizer as possible before good milk can be drawn into the goodmilk line. So in the case of a slow-let-down cow, the second pulsationrate (or pulsation frequency) might be used for a period of time beforetransitioning to good milk being collected in the good milk line.

On the other hand, an easy-let-down cow might not need as muchstimulation at the first pulsation frequency and an adequate amount ofrinsing milk will flow during stimulation. Once the sensor determinesrinsing milk and/or data that shows adequate liner rinsing, thepulsation rate can be changed to the second (more normal) rate and thevalves can be switched to close the waste milk line and open the goodmilk line.

In some cases, the first pulsation rate can be less than the secondpulsation rate or be proceeded or followed by a third pulsation rate.Regardless, other factors can affect teat preparation, such as timing,venting, and others. It is also possible to have a third pulsation rateor a gradually changing pulsation rate leading to the second pulsationrate. A gap in applying pulsation is also possible.

Of course, the present invention ensures proper teat preparation,rinsing and milking of dairy animals, but other aspects of the presentinvention enable operators or inspectors to visually verify properoperation using transparent valves, milk lines, computer displayscreens, or combinations of these.

The present invention protects dairy milk lines and collection systemsby providing: a dairy animal milking apparatus having a milking stallfor receiving a dairy animal, a milker unit having a plurality of teatcups, each teat cup for receiving a respective teat of the dairy animal,a teat wash conduit in fluid communication with at least one teat cup, ateat wash valve assembly in communication with the teat wash conduit,and the teat wash valve assembly is movable between a teat wash positionand a closed milking position, a box wash valve assembly incommunication with the milker unit, and the box wash valve assembly ismovable between a box wash position and a closed milking position, aclean-in-place conduit in fluid communication with the milker unit, aclean-in-place dispenser assembly in fluid communication with the milkerunit and movable between a clean-in-place position and a closed milkingposition, a milk conduit in fluid communication with the milker unit, agood milk valve assembly in fluid communication with the milk conduit,and movable between an open position for passing good milk and a closedposition, a calf milk valve assembly in fluid communication with themilker unit, and movable between an open position for passing calf milkand a closed position, a bad milk valve assembly in fluid communicationwith the milker unit, and movable between an open position for passingbad milk and a closed position, and a controller for opening and closingthe valve assembly to control; teat washing, box washing, clean-in-placewashing, and milking; and for opening and closing valve assemblies tocontrol the flows of good milk, calf milk, and bad milk. A milk factorcan be used to activate the controller, and the milk factor can includea milking time factor, a milk quality factor, and a milking time factorand a milk quality factor.

The invention can further include a milking timer to clock a milkingtime, and in communication with the controller to transmit milking timedata that can be used to open and close the good milk valve assembly,the calf milk valve assembly, and the bad milk valve assembly. The milkquality data can be used to generate the milk factor.

The invention can further include a milk quality sensor to obtain milkquality data on milk from the milker unit, and in communication with thecontroller to transmit milk quality data that can be used to open andclose the good milk valve assembly, the calf milk valve assembly, andthe bad milk valve assembly.

The invention can further include a milking timer to clock milking timeand in communication with the controller to transmit milk time data tothe controller, a milk quality sensor to obtain milk quality data onmilk from the milker unit, and in communication with the controller tosend milk quality data to the controller, and the controller comparesmilk time data and milk quality data to open or close the good milkvalve assembly, the calf milk valve assembly, and the bad milk valveassembly.

The teat cleaning valve assembly can include a first blocking seal, asecond blocking seal spaced apart from the first blocking seal, and ableed vent disposed between the first blocking seal and the secondblocking seal.

The invention can also include a good milk receiver in fluidcommunication with the good milk conduit or a bad milk receiver in fluidcommunication with the bad milk conduit or both. The bad milk receivercan be in fluid communication with the bad milk conduit and the box washconduit, and the good milk receiver in fluid communication with the goodmilk conduit and the box clean conduit.

The invention can also include a bulk tank in fluid communication withthe good milk conduit and the clean-in-place conduit, a clean-in-placedispenser assembly in fluid communication with the bulk tank and theclean-in-place conduit, a milk valve assembly in communication with thegood milk conduit, a branch valve assembly in communication with anddisposed between the good milk conduit and the clean-in-place conduit, amilk wash tank valve assembly in fluid communication with the bulk tankand the branch valve assembly, and a bulk tank drain valve assembly influid communication with the bulk tank.

The invention can also include a proximity sensor disposed to collectteat wash valve assembly data and is in communication with thecontroller to transmit data to the controller.

The invention can also include a milk flow sensor in fluid communicationwith the milker unit and in communication with the controller totransmit milk flow data to the controller, and an air purge in fluidcommunication with the milk flow sensor to at least partially purge milkfrom the milk flow sensor. A milk quality sensor in fluid communicationwith the milker unit can be used, and it can include a milk collectionchamber for receiving a milk sample for quality testing, and the milkcollection chamber defines an inlet for receiving milk at a first flowrate and an outlet for discharging milk at a second flow rate that isless than the first flow rate.

The teat cleaning valve assembly of the invention can include a valveassembly block defining a chamber, a water inlet in communication withthe chamber, an air inlet in communication with the chamber, a bleedvent in communication with the chamber, an outlet in communication withthe chamber, and

a spool disposed for movement at least partially in the chamber, and thespool comprises a plurality of lands and recesses for selectivelyopening and closing the water inlet, air inlet, bleed vent, and theoutlet in relation to the spool's position in the chamber. The spool canbe biased to close the outlet, and it can define a bore in communicationwith the bleed vent when the spool is in a bleed position and incommunication with the outlet when the spool is in a cleaning position.

The clean-in-place conduit can be in fluid communication with the milkcollection system and the milker unit teat cups when the milker unit isin a storage position. A clean-in-place manifold in fluid communicationwith the clean-in-place conduit can be used, so that the clean-in-placemanifold is in fluid communication with at least one milker unit teatcup when the milker unit is in a storage position.

The present invention also overcomes the shortcomings of prior automateddairy animal preparation and milking systems by providing a milker unithaving a plurality of inflations, and each inflation includes a teat cupand a flexible liner. The system includes a sanitizer source, and asanitizer conduit between the source and the inflation. Sanitizerfluids, such as sanitizer, water, and/or air flow through the sanitizerconduit to the inflation where it cleans a teat disposed therein. Usedsanitizer and any accompanying dirt flow down through the inflation,through a drain, and into an appropriate receptacle or disposal system.This is referred to herein as “preparation” or the “preparation stage.”After preparation, the sanitizer conduit and waste collection system aresealed off from the inflation and normal milking operations can begin byopening a line to a milk collector.

Differential pressures in the inflation, and sanitizer conduit andrelated components can draw sanitizer fluids into the milking system. Toprevent this, the present invention provides in the sanitation conduit anumber of valves that are separated by a vent or drain. During thepreparation stage, the valves are open to permit sanitizer, water and/orair to flow through the sanitizer conduit. Another valve closes the ventto prevent sanitizing fluids from flowing out of conduit.

During milking, the valves are closed and the vent is open. Both valvesprevent sanitizer fluids from flowing into the inflation. Nonetheless,even the best valves can be subject to leakage over time due to wear anddifferential pressures on opposite sides of the valve, for example. Inthe present invention, vacuum or other pressure differentials cannotdraw sanitizing fluids through the valves and into the inflation becausethe vent provides air at atmospheric pressure between the valves toobviate the effect of the vacuum.

The downstream valve may suffer from some leakage, but the vacuum orpressure differential from the inflation cannot draw any leakage throughthe upstream valve (closest to the sanitizer source) because theintermediate vent causes pressure in the sanitizer conduit to beessentially at atmospheric pressure regardless of influences from themilk system vacuum. As stated above, this arrangement is sometimesreferred to as “block-bleed-block” because two valves block the conduitand the intermediate vent bleeds the conduit of vacuum and otherpressure differentials. Thus, the milking system is protected from anyvalve leakage of sanitizer fluids.

The sanitizer conduit can communicate with the inflation through inletsin the shell or in the liner, so long as sanitizer fluids reach the teatand are able to wash away from the milking system. The sanitizing fluidscan include sanitizer, water, air or any other suitable fluid. Sanitizeror water can be used first to rinse dirt off the animal's teats. Watercan be used to rinse the teat of sanitizer, and air can be used to drythe teat and push through any sanitizer liquids that remain in theinflation.

Sanitation fluids can be fed to the inflation through a valve assemblythat uses any appropriate type of valves for controlling fluid flow. Thevalve assembly can include valves and vents to perform theblock-bleed-block function.

The system can also be used with any other automated systems such asrobotic machines that attach preparation systems and milker units tocows, as well as, teat dip applicators and backflushing systems asdisclosed in U.S. Patent Application Publication Nos. US 2010-0139723A1, and US 2010-0154900 A1, and U.S. Pat. No. 8,025,029 which areincorporated herein by reference.

One possible functional overview of the present invention when used in arobotic system includes the following: Step 1) Robot Arm ClusterRetrieval; Step 2) Cup Attachment; Step 3) Teat Cleaning; Step 4) TeatDrying; Step 5) Overview of Data; and 6) Print or display of a Summary.

More specifically, the method includes: Step 1: Robot Arm Retrieves aTeat Cup Cluster from Storage Position, when a dairy animal enters themilking box an identification system recognizes a dairy animal as readyto milk; the robot travels to the milking box; a robot arm grasps amilking cluster (milking cups are attached to the milk rack, suspendedabove the floor); and milking cup attachment begins.

Step 2: Milk cup attachment occurs when a 3-D camera locates the teatsand the milking cups and attaches the cups to each teat individually; avacuum sensor detects a positive attachment; if the sensor is notactivated within five seconds, for example the teat vacuum is shut offto that cup and the robot attempts a re-attachment; and pulsation isactive throughout the attachment process.

Step 3: Teat cleaning with sanitization fluids is performed on each teatthrough an orifice in the milking cup; water is applied through theorifice in the cup after the sanitizing solution to rinse the teat andmilk line (for example, fluid flows at approximately three liters/minthrough the orifice); filtered air is admitted through the orifice toflush the line of cleaning solution and debris; pulsation and teat endvacuum are active throughout the cleaning process (strips the foremilkand removes debris from teats); all cleaning solution and any strippedforemilk is directed into a pre-milk (waste) jar; block-bleed-blockvalve configuration separates the pre-milk jar from a good milkreceiver.

Step 4: Teat drying occurs after the teat preparation cycle is finished.A programmable drying time begins and the remaining teat cleaningsolution and foremilk continue to be diverted into the waste jar. Theteats are allowed to dry by means of the applied vacuum and airflow withteat preparation complete, milking begins and programmable stimulationis available for each individual dairy animal.

System advantages for the preparation procedures of the presentinvention include: teat cups remain closed throughout cleaning andmilking, reducing possibility of contamination (no cross-contaminationof teats, nothing can splash onto teats after cleaning, nothing can fallinto milking cups after cleaning—no debris from cow's udder or belly,fly free, and no dirty air, no teat is milked unless it is cleanedfirst); cleaning cycle removes debris and bacteria from teats and milkline—a block-bleed-block valve configuration separates cleaning cyclesolutions from the milk line; unique cluster keeps milking cupssuspended minimizing risk of floor contact; all fluid flows down andaway from the cow; the default path of milk flow is always to the drainbefore diverting good milk to the receiver; barn layout creates a cleardivision of two areas; special needs cows can easily be housed andmilked separately; easily able to attach cows manually; and multi-boxsystem allows shortest milk transfer system possible.

Other advantages and details are described below.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic view of a dairy milking parlor in which there is arobotic milker with a milking machine in accordance with the presentinvention;

FIG. 2A is a perspective view of the milking apparatus of the presentinvention incorporated into a robotic milking machine;

FIG. 2B is a partial perspective view of the milking apparatus of FIG.2A from the opposite perspective;

FIG. 3A is a schematic view of a dairy animal preparation and milkingsystem in accordance with the present invention;

FIG. 3B is a schematic view of a dairy animal preparation and milkingsystem in accordance with the present invention;

FIG. 3C is a schematic view of a dairy animal preparation and milkingsystem in accordance with the present invention;

FIG. 3D is a schematic view of a dairy animal preparation and milkingsystem having a rinsing fluid valve in accordance with the presentinvention.

FIG. 4A is a partial perspective view of a milker unit in accordancewith the present invention;

FIG. 4B is a partial perspective view of dairy animal preparation andmilking system in accordance with the present invention.

FIG. 4C is a partial perspective view of dairy animal preparation andmilking system in accordance with the present invention.

FIG. 5 is a partial cross sectional view of an inflation in accordancewith the present invention;

FIG. 6 is a partial front view of the milking apparatus with some fluidflow paths illustrated;

FIG. 7 is a perspective view of a teat preparation valve assembly;

FIG. 8 is an end view of the teat preparation valve assembly;

FIG. 9A is a cross-sectional view of the teat preparation valve assemblyin a milking position taken along line 9-9 in FIG. 8;

FIG. 9B is a cross-sectional view of the teat preparation valve assemblyin a cleaning position taken along line 9-9 in FIG. 8;

FIG. 10 is an exploded perspective view of a valve for use in a valveassembly in accordance with the present invention;

FIG. 11 is a perspective view of the valve of FIG. 10 in an assembledstate;

FIG. 12 is a side view of the valve of FIG. 11;

FIG. 13A is a cross-sectional view of the valve of FIG. 10 in a closedposition;

FIG. 13B is a cross-sectional view of the valve of FIG. 10 in an openposition;

FIG. 14A is a perspective view of a bad milk valve assembly inaccordance with the present invention;

FIG. 14B is a cross-sectional view of three valves to form a bad milkvalve assembly in a closed position in accordance with the presentinvention;

FIG. 14C is a partial cross-sectional view of three valves to form a badmilk valve assembly in an open position in accordance with the presentinvention;

FIG. 15A is a perspective view of a good milk valve assembly inaccordance with the present invention;

FIG. 15B is a cross-sectional view of three valves to form a good milkvalve assembly in a closed position in accordance with the presentinvention;

FIG. 15C is a partial cross-sectional view of three valves to form agood milk valve assembly in an open position in accordance with thepresent invention;

FIG. 16 is a partial cross-sectional view of a calf milk valve assembly;

FIG. 17 is a schematic view of a milk collection system and aclean-in-place dispenser assembly with representative flow lines inaccordance with the present invention;

FIG. 18 is a front view of a clean-in-place valve arrangement of FIG.17;

FIG. 19A, B, C are front view schematics of the clean-in-place valveassembly in accordance with the present invention;

FIG. 20 is a cross-sectional view of a conductivity sensor for use withthe present invention;

FIG. 21A is a perspective view of a valve block in accordance with thepresent invention;

FIG. 21B is a left side view of the valve block of FIG. 21A withsolenoid valves removed;

FIG. 21C is a side cross sectional left side view of the valve block ofFIG. 21A with solenoid valves removed;

FIG. 21D is a side cross sectional front view of the valve block of FIG.21A with solenoid valves removed;

FIG. 22A is a milk quality chart indicating performance of at least oneembodiment of the present invention;

FIG. 22B is a milk quality chart indicating performance of at least oneembodiment of the present invention;

FIG. 23 is a screen shot of a valve and sanitizing operationverification chart;

FIG. 24 is an alternate screen shot of a valve and sanitizing operationverification chart;

FIG. 25 is an alternate screen shot of a valve and sanitizing operationverification chart;

FIG. 26 is an alternate screen shot of a valve and sanitizing operationverification chart; and

FIG. 27 is a screen shot used by the controller to verify that anappropriate version of the software and/or system is being used.

DETAILED DESCRIPTION OF THE INVENTION

To the extent reasonable and practical, the same identification numeralwill be used to identify the same or similar feature in each of thefigures.

Illustrated generally in FIG. 1 is a dairy harvesting facility 20 havingstalls 22, alleys 24, and milking stalls 26. Dairy animals 27 movethrough the dairy harvesting facility 20 to feed, rest, and be milked inthe milking stalls 26. Control gates 29 can be used to sort cows or toprevent them from entering a particular area. Preferably, an animalidentification system is used to identify cows for sorting andcorrelating to milk, illness, and other purposes.

The milking stalls 26 can be of any shape or arrangement, and bestationary or rotatable. Animals can be allowed to enter the milkingstalls at will or be controlled by gates 29 that are selective based onthe animal's history of milking or health considerations. Animals canalso be moved into the milking stalls 26 by an operator.

In a preferred embodiment of the invention, the milking stall 26 isequipped with a robot 30 (FIGS. 2A and 2B) that attaches the preparationand milking system of the present invention to an animal. Nonetheless,the present invention could be used in any dairy harvesting facility 20regardless of how the system is attached to dairy animals.

In either case, a controller 40 is used to initiate the preparationprocess and fire each valve in an appropriate sequence. The controller40 can also receive data from related sensors and monitors. Data can bestored, printed, displayed or otherwise utilized to improve and monitorpreparation procedures.

In a robotic application, once an animal is identified in the box asbeing an animal acceptable for milking, the robotic milking machine 30travels to the box and removes the milking machine cluster 46 from itscleaning station. The milker unit cluster 46 is moved under the dairyanimal with robotic support arms 38 that can include tubes for vacuum tooperate as indicated below, teats are located and all teat cups 48 areattached to teats. Vacuum with pulsation is applied for a predeterminedtime when searching for a teat. If a teat is located, vacuum andpulsation remain on throughout prep process. If teat is not located,vacuum is shut off and teat location is attempted again.

Illustrated in FIGS. 2A and 2B is the robotic milking machine 30 havinga housing 32, a milking stall 34, a control gate 36, a robotic supportarms 38, a controller 40, a milker unit 46, a key pad 50, a displayscreen 52, a preparation fluid receiver 54, a good milk receiver 56, abad milk valve assembly 60, a good milk valve assembly 62, a box washvalve assembly 66, a calf milk valve assembly 70, a final milker machinevalve assembly 72.

The milker unit 46, milk collecting system, box washing system, andclean-in-place milk collecting and wash system can perform severalsynchronized functions, including: dairy animal teat preparation beforemilking; dairy animal milking; teat dip application, milk and cleaningfluid disposal; milk collection; milking apparatus cleaning; and dairymilk collection system cleaning. Not all of these functions are requiredto support one another, and various individual functions andcombinations of functions are within the scope of the invention becausethey share similar safety features.

Robotic Milking Machine Functions

Generally, the robotic milker 30 operates without an attendant, so adairy animal such as a cow, enters the milking stall 34 on its own, isautomatically secured by the control gate 36, fitted with the milkerunit 46 by the robotic arm 38, prepared for milking by cleaning fluidsflowing through the teat preparation valve 68 that includes a valve set70 for metering sanitizing solution and at least a portion of the milkerunit 46, and then milked by the milker unit 46. A preferred roboticmilking system is available from GEA Farm Technologies GmbH of Bönen,Germany under the brand name MIone.

The milker unit 46 is depicted in FIG. 4A-4C and includes teat cups 48,liners 49, a milk manifold 53, and a milk tube 51 through which fluidsflow downstream. The milk tube 51 is sometimes referred to herein as a“first milk tube.” As milk flows through the milker unit 46, flow rate,quantity, and quality can be determined by appropriate sensors such as amilk sensor such as a blood sensor 63 or a somatic cell sensor 67, akick-off sensor 69, a milk flow sensor 71, a milk meter 64 (See FIG. 3A)that transmit corresponding data to the controller 40. The datatransmitted from the sensors can be used to determine a milk factor thatcan be used to control the operations described herein. The robotic arm38 can serve any number of milking stalls, but only one milking stall 34is illustrated and up to five stalls is preferred. The robotic arm canbe controlled by suitable hydraulic or pneumatic forces.

In a preferred embodiment, animal preparation and milking are bothperformed when the teats are in the milking machine teat cups 48.Accordingly, the present invention includes fail safe precautions toprevent cleaning fluids or contaminated milk from entering the dairy'smain milk handling and storage system where it could contaminate alarger quantity of milk and/or require cleaning of the milk lines, milkchiller, storage containers, valves, and all other milk collectingsystem components. Strict sanitation requirements (3-A SanitaryStandards) are met by the present invention in a number of ways,including material and part selection, part construction, and the valvesystems described below.

Animal Preparation and Milking Operation

Initially, when a dairy animal enters the milking stall 34, a sensorobserves the positions of its teats, relays corresponding data to thecontroller 40, and the controller 40 directs the robotic arm 38 toremove the milker unit 46 from a milker unit docking station 80 (seeFIG. 4C) and position the milker unit teat cups 48 under the animalteats where vacuum in the milker unit 46 secures the teat cups 48 to theanimal teats. Shortly thereafter, the controller 40 initiates a teatpreparation phase by activating the teat preparation valve 68. Cleaningfluids, water, and air are then directed through the sanitizer valveassembly 73 to meter the fluids through conduits to nozzles in the teatcups or teat cup liners to wash and rinse the teats. (Nozzles are notillustrated, but see U.S. Publication 2009/0320760 A1 for an example ofa suitable nozzle arrangement.)

In the milking stalls 22, the robotic system 30 moves a milker unit 46from a cleaning position (FIGS. 4A and 4C) and a milking position (FIG.4B). As seen in FIG. 5, the milker unit 46 includes a number of teatcups 48 and liners 49 inserted within the teat cup 48. The liner 49,includes a dome 61 that defines an opening 65 through which dairy animalteats are inserted.

Each liner 49 is joined to an upstream end of a milk tube 51 that isconnected to the valve assemblies described below.

Vacuum tubes are joined to the teat cup 48 to apply alternating vacuumand venting to a space between the teat cup 48 and the liner 49 andthereby apply a milking action to the dairy animal's 27 teats. Vacuum isalso applied through the liner 49 and the liner 49 to secure theinflation to the animal and to draw milk through these components, thelong milk tube, and the milk lines, referred to collectively herein asthe “dairy system” or “milk system,” in some places below.

Prior to a milking operation, a dairy animal's 27 teats must be cleanedto prevent dirt from entering the inflation and being drawn by vacuuminto the rest of the dairy system. Traditionally, this was done by anoperator, who manually wiped the teats with a towel and/or disinfectant.Automated systems have been used to clean the teats automatically withsanitizer, water, and air, for example.

In a robotic system available from GEA Farm Technologies GmbH of Bönen,Germany, the automated preparation system uses the milker unit 46 liner49 to provide a vessel in which the sanitizing fluids are applied anddrained the present invention adds significant safeguards that preventsanitizing fluids from entering the dairy's milk system. A schematic ofsome of the components of a preferred embodiment of the preparationsystem 80 are depicted in schematic FIGS. 3A-3C.

In FIGS. 3B through 3D, each teat cup 48 has a liner 49. The milk tube51 is illustrated with exaggerated length to show various connections toother components, described below. In practice, robotic systems willhave milk tubes 51 of a variety of lengths, but the short milk tubecould be a standard length. This is especially desirable when sanitizeris used on the teat because sanitizer must be rinsed from the liner 49and the milk tube 51.

FIGS. 3B through 3C further illustrate components of a preparationsystem in accordance with the present invention. The preparation systemincludes at its upstream end, a first sanitizer source valve 89 that caninclude chemical sanitizers, water, air, heat exchangers, pulsators, orother components that can clean animal teats. In the illustratedembodiment, there is a first source 93, a second source 95, and a thirdsource 97. Preferably, generally these represent sources of chemicalsanitizer, water, and air (“sanitizer fluids”), and other fluids can beused within the definition of “sanitizer fluids.”

A second sanitizer source valve 91 can be used (but is not necessary)when it is desirable to add rinsing fluid to the milk tube 51 after teatpreparation and before switching over to milking. The components of thesecond sanitizer source valve 91 can be essentially the same as those inthe first sanitizer source valve 89. (See FIGS. 9A and 9B for an exampleof sanitizer source valve.)

The sanitizer sources 93, 95, 97 are stored in tanks or are availablefrom any appropriate piping system, air compressor, pump, or device thatcan feed these sanitizer fluids, preferably under pressure, to theinflation, as described below.

The sanitizer source 93 is in communication with a conduit 103 and avalve 113, the water source 95 is in communication with a conduit 105and a valve 115, and the air source 97 is in communication with aconduit 107 and a valve 117.

The three conduits 103, 105, 107 communicate with a main sanitizer line109. Although illustrated as separate conduits, the conduits 103, 105,107, 109 could be replaced by or be a portion of a valve block, asdescribed below, for example. The sanitizer line 109 includes adownstream source valve 121 and a vent 123 that can be opened or closedby a vent or drain valve 125.

The first sanitizer source valve 89 is preferably in fluid communicationwith an upper portion of the teat cup liner 49, as illustrated.

The optional second sanitizer source valve 91 is preferably connected tothe system at a location downstream from the teat and more preferablyconnected to the first milk tube 51. The second sanitizer source valve91 might only be used to provide a rinsing fluid to rinse the first milkline 51 of sanitizer and other elements prior to switching over tocollecting good milk through the good milk line. To simplifyconstruction and maintenance, the second sanitizer source valve 91 isconstructed like the first sanitizer source valve 89, even though notall of the sources 93 to 97 are used. This option is described in moredetail below.

Downstream from the liner 49 and in communication with the liner 49directly or via the milk tube 51 is a waste drain system 126 thatincludes a conduit 127, a first waste valve 129, a waste vent 131, and asecond waste valve 133. The vent 131 can be a vent or a drain and ispreferably in communication with atmospheric pressure. Preferably thevent 131 includes a vent valve 137 to prevent waste from draining out ofthe vent 131, but it may not be necessary in all cases to include thevalve 137.

Further downstream, is a milk system shut-off assembly 146 that includesan upstream milk valve 145, a vent 149, and a downstream milk valve 151.As above, the vent 151 can be any vent or drain in communication withatmospheric pressure. The milk system shut-off assembly 146 vent 149preferably includes a milk vent valve 154, but this is not absolutelynecessary.

In the milking position, the first sanitizer source valve 89 (and thesecond sanitizer source valve 91, when used) is closed off from theliner 49 by source valves 113, 115, 117 being closed and downstreamsource valve 121 being closed. The sanitizer vent 123 is open toatmospheric pressure because sanitizer vent valve 125 is opened, aswell. This combination of valve closings and vent openings provides ablock-bleed-block function to prevent milking vacuum from drawingsanitizer fluids into the milking system.

Also, when in the milking position, waste valves 129, 133 are closed andvent valve 131 is open. This provides a similar block-bleed-blockfunction to prevent anything in the waste drain system 126 from enteringor being drawn back into the milk system.

Also when in the milking position, the milk shut-off assembly 146 hasits first and second milk valves 151, 153 open and its milk vent andvalve 149, 153 closed to prevent the milk system vacuum from drawing inatmospheric pressure.

In the teat preparation positions (FIG. 3B), the sanitizer supply systemhas its valves 113, 115, 117 open and its downstream sanitizer valve 121open. The sanitizer vent 123 is closed to prevent sanitizer fluids fromflowing out of the vent 123.

Similarly, the waste system 126 has its first and second waste valves129, 133 open and its waste line vent 135 closed.

To form a block-bleed-block arrangement for the milking system, the milkshut-off assembly 145 has its first and second milk valves 151, 153closed and milk line vent 149 and vent valve 153 open to atmosphere toprevent milk system vacuum or sanitizer pressure from drawing fluidsthrough the milk shut-off assembly 146. The following Chart A is auseful summary of valve and vent positions for milking and preparationprocesses.

CHART A 149, 137, 93 95 97 125 153  131  Teat Potable Clean Vent/ 121147 Vent/ 151 129 Vent/ 133 Sanitizer Water air drain Block Block DrainBlock Block drain Block Step 1 Sanitize O C C C O C O C O C O Step 2 CowRinse C O C C O C O C O C O Prep Step 3 Purge C C O C O C O C O C O Step4 Milk C C C O C O C O C O C CIP C C C O C O C O C O C CIP C C C O C C OC O C O Default nc nc nc no nc nc no nc no no nc O = open C = closed

The first sanitizer source valve 89 and the second sanitizer sourcevalve 91 can be operated simultaneously with all of the valves operatingin unison. Preferably, however, the second sanitizer source valve 91 isoperated in sequence by providing a rinsing fluid to the first milk line51 after air forces most of the sanitizer from the liner 49 and into themilk line 51. Thus, the rinsing fluid will rinse the milk line 51 ofsanitizer and other debris that will be removed through the waste milkline 127. Water, air, and other rinsing fluids can be used to performthis step, but typically, only water is necessary.

FIG. 5 illustrates a cross-sectional view of teat preparation takingplace in a liner 49 inserted at least partially in a teat cup or“shell.” The liner 49 includes an upper dome 61 that fits over the topof the teat cup 48 in a conventional manner. The liner dome 61preferably defines an orifice 161 through which sanitizer fluids,including air, flow on their way to a dairy animal teat 163.

Preferably, the teat preparation valve 68 controls flow of sanitizers,air, and water. Generally, sanitizer is provided first, followed by airto force sanitizer through the delivery system, and then water can beused to rinse the delivery system and the animal teat. Water can beadded through the liner orifice 161, but water or other sanitizing fluidcan be introduced at other locations, including the first milk line 51downstream from the liner 49 from the second sanitizer source valve 91.(See FIGS. 3B, 3C, and 3D, for an example.) Cleaning fluids as well asdirt and debris cleaned from the animal are flushed through the milkerunit 46 and through a milk tube 51, before the dairy animal can bemilked. In one preferred embodiment, a small quantity of milk from theearly stage of milking may need to be sacrificed to ensure that thecleaning fluids and dirt are safely out of the milker unit 46 and milkline 51 before substantially unadulterated milk is collected, asexplained in detail below.

Generally, it is preferred that milk from the animal flows for apredetermined period of time following the sensing of an initial flow ofmilk from a corresponding teat by a conductivity sensor when a thresholdlevel of milk/fluid initial flow sensor is noticed. Milk can then bedirected by the bad (waste) milk valve assembly 60 to a drain or otherwaste milk receptacle. Alternatively or in addition, a milk qualitysensor 63 and 67, for example, (FIG. 3A) can be used to monitor milkflowing from the dairy animal or individual dairy animal teats andtransmit milk quality data to the controller 40 for determining whetherto control the waste milk valve assembly 60 and direct milk to the drainor to control the good milk valve assembly 62 and direct milk to thegood milk receiver 56.

In the illustrated valve and line schematic embodiment (FIG. 3B) firstsanitizer source valve 89 includes valves V6, V8, V10 that are closed,and valves V7, V9, V11 are open. Preferably, all preparation processesand switching from “bad milk” to “good milk” are done on individualteats, but data from other teats can be used, as described below.Optionally, the second sanitizer source valve 91, like the firstsanitizer source valve 89, is provided to direct a rinsing fluid to thefirst milk line 51 via a rinsing fluid connection 111. Rinsing fluid caninclude sanitizer, water, air, or any other suitable rinse.

In the present invention, it is useful to verify that the system isoperating as designed, so that there is no contamination of milk or goodmilk lines. There are a number of ways to verify acceptable operatingconditions. One way, is to view a controller display of valve positionsfor the valves in the good milk lines and the waste lines. A preferred“screen shot” is illustrated in FIG. 23, provides verification of propervalve function and position, which can be visually monitored becauseeach valve is represented on a screen. Alternatively or in addition, allvalves can be transparent and/or have LED indication position sensing,such as LED being on indicates valve is in safe position for milkinginto good milk tank.

The screen of FIG. 23 also shows the robot system controller 40 andaccess box monitoring screen to observe valve status and position sensorstatus in real-time.

The screen depicted in FIG. 23, shows all valves, block-bleed-blocksensors, blood and conductivity sensors and their respective status.Preferably, valves can also be operated by an operator by pressing asymbol near the bottom and then selecting any valve for manual operationor sensor function.

In FIG. 3B, valves V1, V2, and V3, through which the teat preparationsanitizer flows, are enabled by closing valve V4 and opening valve V5.Valves 6, 7, and 8 provide the double block protection from good milkand are position confirmed on the screen as colors, shapes, symbols,icons, or other visible or other type of sensory indicator. In apreferred embodiment preparation solution at 35 psi is dispensed for 120milliseconds to deliver 5-8 ml of sanitizer into the delivery hose.Verification of this step on a controller screen shows valve functionand position monitored in the same manner as above.

Teat sanitizer pressure is preferably monitored by checking a pressuregage located at a solution air pump next to a solution supply drum (notillustrated). A valve “on-time” value can be confirmed on the controller40 automatically by accessing the expert parameters screen (FIG. 25).Teat sanitizer volume can be manually verified by plugging the teat cup48 and removing the sanitizer delivery hose from the teat cup 48,pointing it into a graduated cylinder, initiating the prep cycle with acow ID responder that is entered in the controller 40 to simulate ananimal ready to be milked. With the sanitizer delivery hose stillpositioned over a graduated cylinder, sanitizer can be dispensed intothe graduated cylinder and measured for volume. If out of apredetermined range, the sanitizer volume can be adjusted in thecontroller 40, through a dosing valve, or other suitable means.

Preferably, valve V3 provides 5 to 10 psi oil-free clean filtered air topush the sanitizer to the teat and distribute it around the teat as muchas possible. Teat sanitizing is accomplished by flowing sanitizingfluids past the teat while the first pulsation is being applied by apulsator 92, but other pulsation rates can be used. Preferably, airflows (pulled by a vacuum in the milk line) for 10 seconds for thesanitizer to the teat, distribute it around the teat, and force excesssanitizer to a waste line. The sanitizers preferably flow into the headof the liner 49 from valves V1 and V2 and can be directed all around theteat by geometry inside the liner head, as disclosed in U.S. applicationSer. No. 12/215,706, for example. The first pulsation rate can continuethroughout the entire preparation process to enhance movement ofsanitizer onto all teat surfaces, to aid in loosening and removal ofdirt from the teat, and to attempt stripping foremilk from the teatprior to other “good” milk being drawn from the teat. Valves V1 to V5 inthe first sanitizer source valve 89 and/or in second sanitizer sourcevalve 91 (also referred to herein as a “rinsing fluid valve”) thenreturn to a “safe” position, creating a double seal of the teatsanitizer delivery system from the good milk line. Between the doubleseal, there is preferably a vent so that the block-bleed-block functionis performed in the “safe” position.

Verification of these events shows valve function and position monitoredin the same manner as above. A set value for teat sanitizer delivery andair purge time can be verified as seen on the Milk Safety P6=12, whichis 120 ms of time in FIG. 24. P7=1000 ms is the air chase or purge timewhich is calculated to 10 seconds or air valve on-time. Pressure of theair can be confirmed by looking at the pressure gage on the controlleror other suitable location. Teat sanitizer delivery pressure can bechecked by looking at the pressure gage located at the air operated pumpnext to the sanitizer supply drum or any other suitable location. Theabove described operating conditions are suitable for use with asanitizer known as OxyCide AMS, a 1% hydrogen peroxide solution,available from GEA Farm Technologies, Inc., 1354 Enterprise Drive,Romeoville, Ill. 60446, which is a hydrogen peroxide sanitizer.

Teat drying and sanitizer contact duration (“kill-time”) take place byallowing air to be drawn into the liner 49 from an air bleed located inthe sanitizer delivery system. This air flow provides a constant dryingprocess during the kill-time and can be used throughout the milkingprocess. Based on laboratory tests, OxyCide has a 95%+ kill of Staph.and Strep. organisms within five seconds, so the necessary kill-timeelapses during the previous 10 second distribution and excess purgingprocess. Teat drying takes place until good milk flow is directed to thegood milk line.

The above-described parameters can be checked via an air bleed ventlocated on the bottom end of the prep safety valve of the illustratedembodiment. To verify a valve is admitting air, an operator can simplyplace a finger over the vent or “bleed” during milking or when applyingvacuum with teat cup plugged.

The process preferably purges the milk hoses of prep solution andrinsing milk, a minimum of one “slug” of milk is used to purge remainingsanitizer and rinsing milk from the liner 49. The term “rinsing milk”refers to foremilk and/or good milk, and can include sanitizer, air, anddebris from the sanitizing process, but other elements may be includedas well. The rinsing milk slug is routed to waste milk line throughvalves V9, V10 and V11. (FIG. 3B.)

It is desirable to avoid using good milk to rinse sanitizer from theteat liner. One method for minimizing waste is to introduce rinsingfluid into the liner to rinse sanitizer and thereby avoid using goodmilk for this purpose. The rinsing fluid can also be introduced to thefirst milk tube 51 downstream from the teat so that only first milk tube51 is exposed to this rinsing fluid.

The terms “rinsing milk” and “rinsing fluid” are used interchangeablyherein and those terms can include combinations of the two.

Further, the first milk line 51 can be any desired length or it can beany type of flow directing device that leads to the waste milk line orgood milk line. The first milk line 51 can include a rinsing fluidconnection 111, when a second sanitizer source valve 91 is used.

Slugging of milk is enhanced through the use of pulsation and liner 49manipulation/stimulation. When the teat cup 48 and liner 49 are attachedto a teat, the liner pulsation rate (induced by the pulsator 92) ispreferably increased to a first pulsation rate or frequency. This causesthe liner 49 to stay mostly collapsed on the teat and helps to close theteat canal, while providing a stimulating message. Good stimulation issometimes performed for up to 90 seconds to ensure fast and completemilking. Therefore, the first pulsation frequency can be used as astimulation process for up to 90 seconds or even more if necessary. Thenthe first pulsation rate transitions to a second pulsation rate that isalso induced by the pulsator 92 and is preferably a normal pulsationrate, but can be any other pulsation rate that enhances the transitionfrom teat preparation and liner rinsing to milking. Sensors, such asflow or milk quality sensors, can be used to monitor rinsing milk orfluid flow and prevent switching from collecting rinsing fluid to goodmilk until a required level or time of flow or other rinsing fluidproperty is achieved.

The process of the invention is useful in cows that are slow to beginmilking. These animals are sometimes called “Slow let-down cows.” Somecows may be nervous or in general are slow initial flow milkers. Theirinitial milk flow rates should be enhanced to provide good efficientrinsing of sanitizer from the liner and efficient milking. The linermanipulation/stimulation helps to promote oxytocin release in the cowwhile helping to minimize milk flow at the early preparation stage.

Milk from slow let-down cows collects in the teat cistern while udderpressure builds. Preferably, after up to about 90 seconds ofstimulation, there is a transition to the second pulsation rate, andmilk flow typically is improved, resulting in more efficient rinsing ofsanitizer from the liner 49. As rinsing fluid flow continues, sensorsindicate when a minimum flow time, rate, volume, mass or other property,has been achieved that ensures that sanitizer is rinsed from the liner.Then the controller 40 causes the decision valves to switch the milkflow from the waste milk line to the good milk line.

On the other hand, some cows are ready to be milked shortly after themilk cup 48 and liner 49 are attached. These animals are known as “Easylet-down cows.” Some cows come into the milking box with high udderpressure and a tendency of easy milk let-down. In this case, goodslugging and purging of prep solution can happen without the typical 90second stimulation time. If rinsing fluid flow is sufficient during thestimulation time, indicating good pressure and rinsing fluid flow forproper sanitizer purging, the decision valves switch from the waste milkline to the good milk line. In this case, good milk flow should not beheld back for up to 90 seconds to prevent waste. Wasting additional goodmilk is avoided by monitoring sensors throughout the preparationprocess, and/or switching to the second pulsation rate when properrinsing is achieved.

As stated above, it is also desirable to avoid using good milk to rinsesanitizer from the teat liner. One method for doing so, is to introducerinsing fluid into the liner to rinse sanitizer and thereby avoid usinggood milk for this purpose. The rinsing fluid can also be introduced tothe first milk line downstream from the teat using the second sanitizersource valve 91, as illustrated in FIGS. 3B and 3C, for example. Thisassumes the liner 49 is satisfactorily rinsed and only the first milkline 51 needs rinsing. Further, only water may be introduced by thesecond sanitizer source 51. Other locations of rinsing fluidintroduction are possible.

Verification of this process is possible on a controller screen thatshows valve function and position monitored in the same manner asdescribed above, by visually watching valves and sensor LEDs on thevalves, and/or accessing a monitoring screen 50, 52 in communicationwith the controller 40. The presence of the milk slug prior to switchingfrom the first pulsation frequency to the second pulsation frequency canbe visibly monitored through clear milk hoses and clear valve bodies, ifdesired.

The screen capture illustrated in FIG. 25 shows information like thatdiscussed above for each teat, and it can include flow totals, ifdesired. In the depicted embodiment, clicking on an “Expert Page 1” inthe lower right of the display, allows an operator to monitor milk flowsensors and transition to good milk information for each teat (or each“quarter”).

The teat liner 49 is put into milking mode and milk is allowed to flowto the good milk line through the switching of various block-bleed-blockvalve arrangements on a teat-by-teat basis, if desired. This is achievedin the illustrated embodiment with valves 1, 2, 3, 5, 7, 9, 11 of thefirst sanitizer source valve 89 and/or second sanitizer source valve 91closed, and valves 4, 6, 8, 10 opened to make this transition.

Another way to monitor the operation is to access the controller 40 boxmonitoring screen 50, 52 to observe valve status and position sensorstatus in real-time, as described above. The screen illustrated in FIG.26 illustrates blood monitoring as well as other milking information.

After each teat is milked and the teat cups 48 have been removed, theteat cup assembly preferably returns to a jetter rack (docking station,80) where all cups 48 are sanitized and backflushed into the prep fluidreceiver 54. The prep fluid receiver 54 is drained to a waste line. Thiscan be verified (as above) by visually monitoring the operation directlyor on the controller screen 50, 52. Waste draining can be viewed byobserving end of hose at bottom of prep fluid receiver 54, for example.

Controller Logic

The screen in FIG. 27 illustrates where the software version can beverified. To transition from draining to the waste line to the good milkline, it is possible to monitor various rinse milk and/or rinsing fluidproperties including, flow duration rate, volume, conductivity, mass,slug counts, and combinations of these, for example. It is preferredthat no parameters can be easily accessed or changed that have anythingto do with the preparation process due to the risk of contaminating goodmilk lines. All parameters that control the sanitizer delivery, valveswitching from rinsing fluid to good milk, or the decision makingparameters of the controller related to purging sanitizer can not bechanged by the customer or technician without the assistance of atrained controller programmer.

Cleaning Individual Milk Stall Lines

After the milking operation is complete, the process repeats itself onthe next dairy animal, unless the milk or milk lines are in need of ascheduled cleaning or were contaminated by cleaning fluids orcontaminated milk (including milk with mastitis). In such a case,individual stall milk lines are cleaned, which is sometimes referred toas “box washing”. Box washing is a term used to describe a washing ofonly the components of an individual milker unit 46 or a number ofmilking apparatus, as opposed to the dairy's larger milk collectingsystem 33.

The box washing phase can be initiated when the controller 40 receivesdata from the sensors 63, 67, 69, and 71, for example (FIG. 3A) that boxwashing is necessary, in response to predetermined wash intervalsprogrammed into the controller 40, in response to operator interventionor the most recently milked animal is designated as being unhealthy orundergoing medical treatment, for example.

To initiate the box washing phase, the box wash valve assembly 66 isactivated by the controller 40, and wash fluids are pumped from nozzles82 in the docking station 80, into the teat cups 48, and then throughthe milker unit 46, and to the preparation fluid receiver 54. Cleaningfluids are circulated through the good milk receiver 56 and thendischarged through a calf milk drain. Preferably, the milker unit 46 ispositioned by the robotic arm 38 at the docking station 80 (FIG. 4C).

As seen in FIG. 4C, the docking station 80 is mounted to the robothousing 32 and adjacent to the milking stall 34. The docking station 80includes nozzles 82 that are inserted into the teat cups 48 so thatcleaning can take place. The docking station 80 also includes a flexibleflange 84 that mates with the top of a corresponding teat cup 48 to forma seal. Milk line vacuum secures the teat cups 48 to the flanges 84.

Controller Functions

The controller 40 preferably controls operation of the above-describedcomponents, as well as those described below in response to itsprogramming, timers, and data received from various sensors, forexample. The controller 40 is preferably programmable with at leastinitial process steps for teat preparation, milking, and washing, usingpredetermined sequences and timing for these operations. The controller40 can be a central processing unit (“CPU”), printed circuit board orany other suitable device.

The preparation and milking sequences can be set and maintained for alldairy animals to be milked or programmed to perform the steps in aunique fashion for specific cows. Individualized programming can bebased on each animal's lactation cycle, milking characteristics, healthor other unique characteristic. A dairy animal identification system cansend data to the controller 40. The controller 40 can also use “fuzzylogic” to adjust teat preparation, milking, and washing based on anydesired dairy or dairy animal feature and thereby continually adjust towhatever conditions are present.

Further, the controller 40 includes an operator interface, such as thedisplay screen 52 to display any relevant information, such as,historical data, dairy animal information, current process data, and soon. Audible alarms and/or speakers can also be used. The controller 40can be programmed, activated, and deactivated by an operator foroperation. Preferably, the controller 40 initiates automatically when adairy animal enters the milking stall 34. The display screen 52 can alsodisplay various features of the milking operation, warnings or any otherinformation relating to the robotic milking machine 30, the animal beingmilked, udder quarters being milked, animal health, and animal controlgates. Displays can take on any appropriate format and may be unique tosuit the needs of any particular dairy.

The controller 40 also preferably receives data from sensorscorresponding to a cow identification, gate position, animal position,system operability, animal health, valve positions, milk times, milkquantities, preparation time and sequence, wash chemical supplyquantities, as well as any other desired feature. The controller 40compares these data to predetermined criteria and can then continuewithout change, adjust a process, deactivate one process, initiateanother, or make determinations about where to route milk from the dairyanimal, for example.

Fluid Flow Paths

In the present invention, dairy animal teat preparation is performedautomatically before milking begins. As stated above, the milker unit 46is used for the preparation process and for milking. Flow paths forcleansing fluids, contaminated milk, calf milk, and milk for humanconsumption are described below.

As seen in FIG. 6, the teat cups 48 are at the “upstream” end of themilker unit 46. Downstream from the teat cups 48 are the milk tubes 51and the manifold 51A. The milk tube 51 is in fluid communication withboth the bad milk valve assembly 60 and the good milk valve assembly 62so that “good” milk and “bad milk” can be handled appropriately.

Further, for the teat preparation process, the milker unit 46 is incommunication with the teat preparation valve 68. The teat preparationvalve 68 is activated to deliver teat wash chemicals, solutions, and air(“teat preparation fluids”) upstream through a suitable teat preparationconduit through which the teat preparation fluids flow to an outlet thatis either positioned on the teat cup or through the teat cup liner. Theteat preparation fluids are preferably delivered near the top of eachteat so that they flow downward with any dirt or debris into the liner49, and milk tube 51 from where they are disposed of or retained, asdescribed below.

Next, the milking operation begins, but for hygiene reasons, it is notassumed that all of the teat preparation fluids are rinsed out of themilker unit 46. To ensure a sanitary milk flow path, some milk from thefirst portion of the milking cycle is used to “rinse” the milker unit 46and through the bad milk valve assembly 60. The amount of milk used forthis “milk rinsing” operation can be determined in a number of ways,including empirically. Milking for a predetermined period of time fromthe start of milking can be replaced or augmented with milk qualitytesting using milk quality sensors 63, 67. The milk quality sensors 63,67 gather data indicating whether the milk satisfies a predeterminedquality standard. The data is transmitted to the controller 40, whichdirects the milk to an appropriate receptacle by opening or closing thebad milk valve assembly 60 and good milk valve assembly 62.

When milking time and/or quality data meet predetermined standards asdetermined in the controller 40, then the controller 40 opens or closesappropriate valve assemblies to direct the milk to the good milkreceiver 56. This directing of milk is performed by the controller 40 toopen and close appropriate valve assemblies, as described in more detailbelow. Calf milk can be directed through a calf milk conduit and/orstored in an appropriate receptacle. This decision can be made by thecontroller 40 or by an operator.

From the good milk receiver 56, milk passes through a conduit 90 (FIG.6) to the dairy milk collecting system 33. Milk can be retained in thegood milk receiver 56 until it is determined that it meets qualitystandards, such as cleaning downstream from the milking apparatus 42,are performed. This is particularly advantageous in robotic systemsbecause milking can continue despite there being incompatible processesoccurring elsewhere in the dairy.

Valves

The present invention includes a number of components in each milkingapparatus to ensure that sanitary conditions are met. Some of theprimary components include three subsystems: teat preparation valve 68,a bad milk valve assembly 60, a good milk valve assembly 62, and a boxwash valve assembly 66. Preferably, each valve assembly is positioned inpiping, tubing, or other type of conduit that is connected directly orindirectly with the milker unit 46 and satisfies 3-A Sanitary Standards.

The valve assemblies of the present invention can have variousconfigurations, but valve assemblies through which milk flows preferablyhave three valves in series and each valve moves between opened andclosed positions (or sometimes referred to below as milking or washingapparatus). The position of each valve in a valve assembly at any giventime is determined and controlled by the controller 40. Position sensors116 verify that a valve is in its desired position so that valvemalfunctions and/or normal wear do not cause milk or cleaning fluids tobe misdirected. The valve assemblies for milk handling can be used forall of the milk from an animal, from individual quarters or pairs ofquarters. The robotic milker illustrated in FIGS. 2A and 2B have valvearrangements for individual quarters. Thus, for a single animal, therewill be four assemblies of three valves each, for a total of twelvevalves. Valve assemblies for teat preparation fluids and washing systemsdo not necessarily require the three valve assembly and are alsodescribed in detail below.

Teat Preparation Valve

As illustrated in FIGS. 7 to 9B, the teat preparation valve 68incorporates a block-bleed-block arrangement to ensure safety from valvefailure.

Preferably the first sanitizer source valve 89 and the second sanitizersource valve 91 have the configuration of the teat preparation valve 68,described below. The teat preparation valve 68 is mounted using abracket 99, and preferably is contained within a housing 100. As seen inFIGS. 9A and 9B, the housing 100 has a bore 102, a spool 104 disposedfor axial movement in the bore 102, a fluid inlet 108, an air inlet 110,a bleed vent 112, an outlet 114, and a proximity switch 116. FIG. 9Aillustrates the teat preparation valve 68 in a closed position and FIG.9B illustrates the teat preparation valve 68 in an open position.

Generally, when in the open position (FIG. 9B) preparation fluid, suchas water and/or cleaning fluids, are pumped through the fluid inlet 108and out of the outlet 114, during a cleaning operation. If desired, anair slug or purge can then be pumped through the air inlet 108 and outthrough the outlet 114 to push cleaning fluids to their destination.

The housing 100 preferably includes a body 120 formed or machined in asingle piece or multiple pieces disposed between two ends 122, and theseparts are secured with appropriate connectors, such as hex bolts 124 andnuts 119. Appropriate seals 130, such as o-ring seals, are disposedbetween the body 120 and each end 122. The housing 100 is preferablyshaped and constructed as illustrated, but other shapes and arrangementsare possible. Nonetheless, the illustrated embodiment is sized to fitinto the robotic milking machine 30.

Whether the inlets 108, 110, vent 112 or outlet 114 are opened (FIG. 9B,cleaning operation) or closed (FIG. 9A, milking operation) depends onthe position of the spool 104 within the bore 102 because the spool 104includes lands and recesses that are spaced apart and positioned intheir desired locations as the spool 104 moves. Not all of the inletsneed to be used. For example, the second sanitizer source valve 91 mightonly use a water inlet because it may not be necessary to add asanitizer to the first milk tube 51. As depicted in FIG. 9A, the inlets108 and 110 are closed by lands 132 and 134, respectively. Each land132, 134 is separated from the other by a pair of spaced apart seals 136with a vent opening 138 disposed in between the seals 136 to form ablock-bleed-block arrangement. The seals 136 are preferably u-cup seals,but other types of seals can be used.

In the milking position, a slot 140 is positioned adjacent to the bleedvent 112, which itself has a pair of seals 144 disposed on each side toform the block-bleed-block arrangement. In FIG. 9A, the outlet 114 isblocked by a land 132. The slot 140 is sized to provide a desiredsequence and timing of operation as the spool 104 moves back and forth.Other arrangements could be used to meet these operation criteria.

The spool 104 is biased toward the closed or milking position asdepicted in FIG. 9A by a spring 150. To open the teat preparation valve68, pressurized air is allowed into the bore 102 to urge the switch 116to move the spool 104 against the bias of the spring 150 (to the left,as viewed) to allow preparation fluid to flow through the fluid inlet108, the vent opening 138, and a central bore 162 in the spool 104. Whenin the open or cleaning position (FIG. 9B), the slot 140 is aligned withthe outlet 114. Minor calibration adjustments of the spool 104 are madepossible by an adjustment screw 166 that sets the limit of spoolmovement that can be caused by the spring 150.

Single Seat Valves

A valve arrangement of the present invention is used along milk flowpaths and preferably includes an assembly of three “single seat valves.”These assemblies are used in the bad milk valve assembly 60, the goodmilk valve assembly 62, and the box wash valve assembly 66, for example,but they are also used in other locations described below.

As illustrated in FIGS. 10 to 13B, single-seat valve 198 is preferablythe same size and construction as the others to reduce manufacturing andmaintenance costs. Referring to the exploded view of FIG. 10, the valve198 includes from left to right: a cylinder 200, an air fitting 206, avent fitting 208, a spring 212, a first e-ring 216, a lower guide 244, afirst u-cup seal 228, a second e-ring 236, a second seal 238, an upperguide 260, a third seal 254, a molded lip seal 234, a third o-ring seal262, a plunger 264 with a head 265, a clamp 266, a fourth seal 268, anda body 270. The body includes three openings arranged in a T-shape. Theopenings are labeled 272, 280, and 284 in FIG. 10 and they may beinlets, outlets or permanently blocked in any given valve assembly,examples of which are described below.

The single seat valve 198 is assembled by inserting the plunger 264through the various internal parts and securing them together with thefirst and second e-rings 216 and 236 to recesses 271 and 273 in theplunger 264. The cylinder 200 is secured to the body 270 by the clamp266. Other arrangements and connections for the internal and externalparts of the single seat valve 198 are within the scope of the presentinvention.

In FIGS. 12, 13A and 13B, the valve 198 is shown with the cylinder 200secured to the body 270 with the clamp 266. Generally, each opening 272,280, and 284 can be an inlet or an outlet. A pass through bore 286 canbe opened at only one end or at both ends, depending upon its positionin the valve assembly. The valves 198 can be joined at appropriateflanges 287. To open or close the valve 198, the plunger 264 is moved ina longitudinal axial direction so that the plunger head 265 engages aseat 285 in the body 270 or the plunger head 265 is spaced apart fromthe body seat 285.

The plunger 264 is kept in alignment by the upper guide 260 and thelower guide 244. The spring 212 acts on the lower guide 244, to bias theplunger 264 toward the closed position, as seen in FIG. 12. The upperguide 260 is mated into an extension 287. The extension 287 defines anumber of openings 288.

When the valve 198 is opened, the plunger 264 is moved against the biasof the spring 212 with air pressure exerted through the air fitting 208onto the lower guide 244. As a result, the plunger head 265 is moved outof engagement with the seat 285, and fluid can flow in or out of opening272. When the valve 198 is closed, the plunger head 265 is engaged withthe valve seat 285, so that fluid cannot flow out of the opening 272,but can flow past the plunger 264 in the pass through bore 286.

The valves 198 are used in sets of three and preferably are arranged toprovide a block-bleed-block function at each valve assembly as seen inFIGS. 13A-C, for example. In this embodiment, the outlet 284 in valve198A is permanently blocked by a wall 297, and the opening 280 in valve198C is permanently blocked by a wall 297. In a three valve assembly,the two “outer” valves 198A and 198C are open (FIG. 13A) and the valve198B is closed to provide a pass through between valves 198A and 198C.In FIG. 13B, the valve 198B in the middle is open to provide a vent or“bleed” through the outlet 272 of the middle valve 198B, and the valves198A and 198C are closed to provide “blocks” on opposite sides of the“bleed” created by valve 198B. Thus, the three valves subassemblies198A-C cooperate to form a block-bleed-block safety feature.Alternately, the three valves 198A-C can be disposed in a singlehousing, but as depicted, they provide a relatively inexpensive option.

Proximity sensor 294 is preferably used to indicate to the controller 40that the plungers 264 are in the desired position. (See FIGS. 13A and13B.)

The chart below illustrates each valve 198A-C position related to thevalve assembly position as a whole.

Valve Assembly Position Valve 198A Valve 198B Valve 198C Closed Closedto Open to Open Closed to Block Nipple Vent Block Nipple Open OpenClosed to Block Open Nipple Vent

The example of valve assembly operation illustrated in FIGS. 13A and 13Bincludes flow lines A and B representing the direction fluid flows. Moreparticularly, examples of operation for assemblies of valves 198 includethe bad milk assembly 60 and the good milk assembly 62.

Referring to FIG. 6, milk from the milker unit 46 flows through the milktube 51 to a branch that permits milk flow in two directions, butdepending on whether the bad milk valve assembly 60 and the good milkvalve assembly 62 are opened or closed the milk will flow in only onedirection. Only one of these valve assemblies will be open duringmilking, and the other will be closed.

If the controller 40 determines that the fluid flowing is teatpreparation fluids or contaminated “rinse” milk, the good milk valveassembly 62 will be closed and the bad milk valve assembly 60 will beopen.

Bad Milk Valve Assembly

In the bad milk assembly 60 illustrated in FIGS. 14A-14C, fluid entersthe inlet on valve 198A through the opening 272 and out through the passthrough bore 286, which is joined to the pass through on valve 198B.Fluid flows through the valve 198B bore 286, into the valve 198C bore286, and out of the opening 272. The valves 198A-C are illustrated asbeing joined directly to one another, but suitable conduits can be usedin between them.

From the valve 198C opening 272, the fluids flow through bore 286, andinto the wash fluid receiver 54. From there, the wash fluids and/orcontaminated milk can be directed to a drain 296 or other suitabledisposal apparatus.

If the controller 40 determines that the milk flowing through the milktube 51 is good (meets predetermined quality standards), the bad milkvalve assembly 60 will be closed and the good milk valve assembly 62will be opened.

In the closed position, bad milk valve assembly 60 has valve 198A in aclosed (block) position, valve 198B in a vent position, and valve 198Cin a closed (block) position to provide the block-bleed-blockarrangement described above.

Good Milk Valve Assembly

Referring to FIGS. 15A-15C, the good milk valve assembly 62 is in anopen position when its: valve 198A is open; valve 198B is sealed fromatmosphere; and valve 198C is open. In the good milk valve assembly 62closed positions, valve 198A is closed, valve 198B is in a ventposition, and valve 198C is closed, for block-bleed-block.

When the good milk valve assembly 62 is in the open position, good milkflows into the opening 272 of valve 198A, out of the valve 198A passthrough bore 286, through the bore 286 of valve 198B, and through thebore 286 and opening 272 of valve 198C. From there, the good milk flowsthrough a good milk conduit 300 and into the good milk receiver 56 viaits inlet 308.

Good Milk Flow Path

Good milk can remain in the good milk receiver 56 for a period of timefor quality testing or to serve as a “buffer” tank when the dairy milkcollecting system 33 is off-line, as described above. When desired, goodmilk flows from the good milk receptacle outlet 314, through the conduit316, and through a pass through conduit 320 in the box wash valveassembly 66, which is explained in more detail below.

From the box wash valve assembly 66, the good milk flows to a conduitjunction 330 where it flows to the dairy milk collecting system conduit332 or to a bad milk conduit 334, depending upon which of the good milkvalve assembly 62 or the bad milk valve assembly 60 is open. When one ofthese valve assemblies is open, the other valve assembly will be closed.

From the good milk line 300, the milk can go either to the dairy milkcollecting system or to a calf milk line 340. Suitable block-bleed-blockvalve assemblies, like those described above and illustrated in FIG. 16,are preferably used to segregate good milk and calf milk.

FIG. 16 illustrates a valve assembly for a calf milk flow path. Akick-off sensor senses the existence or absence of vacuum and willsignal the controller to initiate an appropriate action.

Dairy Milk Collecting System

The schematic view of a milk collection system 33 as depicted in FIG.17, illustrates additional general components of a dairy milk collectingsystem 33, which is downstream from the good milk receiver 56 andreceived via conduit 399. As seen in FIGS. 17-18, the milk collectingsystem 33 includes a milk pump 400, a milk pre-cooler 402, a coolingtank valve assembly 410, a clean-in-place spray ball 412 (or othersuitable water inlet deflector), a clean-in-place line 414 with a valveassembly 413 returning to the robotic milking machine 30, a cooling tank430, and a second valve assembly 415 and appropriate conduits anddrains.

The cooling tank valve assembly 410 (FIGS. 19A-19C) preferably includesfive valves 420, 422, 424, 426, and 428. The following chart indicatesvalve assembly positions in the milking position, clean-in-placeposition, and cooling tank wash position that allows the good milkreceiver 56 to act as a buffer tank while the cooling tank 430 is beingwashed, so milking operations can continue during cooling tank 430washing.

Valve Milk Position CIP Position Cooling Tank Wash 420 Open Open Closed422 Open Closed Open 424 Closed Open Open 426 Closed Closed Open 428Closed Open Closed

Preferably each valve 420-428 is a block-bleed-block valve assembly, asdescribed above, and includes a pair of spaced apart valves 198A and198C with a bleed valve 198B in between. Block-bleed-block valveassemblies are preferred because they prevent wash fluids and bad milkfrom flowing past valve seals and into other dairy lines, as describedabove.

Clean-in-Place Dispenser Assembly

As illustrated in FIGS. 17 and 18, clean-in-place dispenser assembly 500in accordance with the present invention preferably includes: chemicaltanks 549, chemical dispenser 551, check valves 553, a sensor 555, amounting plate 558 on which are mounted a hot water valve 560, a coldwater supply 562, a three-valve assembly 568, an air purge 570 forpurging the clean-in-place dispenser assembly 500 and to push water intoa flow diverter 576 in a cooling tank 430 to remove milk film from thetank's interior surfaces.

FIGS. 18, 19A, 19B and 19C illustrates flow paths of fluids through theclean-in-place dispenser assembly 500. Water of a desired temperatureand pressure, proceeds along a flow path 501. Wash chemicals proceedalong flow path 502 and air proceeds along flow path 503. As is apparentfrom FIG. 18, the flow paths 501, 502, and 503 begin at different inlets510, 511, 512, and 514, respectively, and all are dispensed throughoutlet 516. The water, chemicals, and air are provided to theclean-in-place dispenser assembly 500 at appropriate sequences, volumes,pressures, temperatures, and durations. These factors vary for eachsystem due to size, conduit lengths, ambient temperatures, cleaningchemical selection, and other considerations.

A clean-in-place dispenser valve assembly 500 is arranged similarly tothose described above, and each valve 198A, B, C serves substantiallythe same function as described above. In this particular clean-in-placedispenser valve assembly 500, the valves 198A and 198C are closed duringmilking and when milk is stored in the cooling tank 430. The valve 198Bis opened to provide a vent in a block-bleed-block relationship.

During cleaning, the valves 198A and 198C are opened, and valve 198B isclosed. Due to the pass through bore 286, fluid flows through valve 198Bwhen it is closed. Chemical flow sensor 564 is also used.

Milk Flow Sensor

Suitable sensors for use in the present invention include conductivitysensors that detect and/or measure flow quantity and/or rate, as well assensing milk quality as milk flows from or through the milking machine.A preferred suitable conductivity sensor 600 is illustrated in FIG. 20and includes a housing 602, a bore 604, a reservoir 606 in which aconductivity probe 608 is positioned, and a slot 616 that is sized somilk can drain from the reservoir 606, but is small enough to slow flowto a rate at which a conductivity measurement is possible. The slot 616is also preferably sized large enough so that sand, dirt or grit in thereservoir 606 can be carried out by the milk. This arrangement preventsclogging and malfunction of the conductivity sensor 600, and yet is ableto slow milk flow long enough for conductivity data to be received.

Hoses used in the present invention are preferably vulcanized withstainless steel fittings and with hoses from STI Components, Inc. ofMorrisville, N.C., for example. Other hose connections and manifolds arepreferably continuously welded and finished to 3-A Sanitary Standards.

Another suitable valve block 610 for use in dispensing sanitizer fluidsis depicted in FIGS. 21A to 21D. FIGS. 21A through 21D illustrate avalve block 610 in which a number of valves are provided for supplyingmultiple sanitizer fluids (air, water, and sanitizers) through a commonoutlet 637 to the sanitizer line 128. The valve block 610 includes ahousing 613 that defines an axial chamber 619 in which a spool 621 isdisposed to slide between a milking position (FIG. 21C) and a sanitizingposition (FIG. 21D). The axial chamber 619 includes an upper bellportion 623 and a lower bell portion 625.

The housing 613 is preferably oriented vertically, as depicted, toprovide drainage of fluids through a drain 634 (FIG. 21B), but otherorientations can be used. Preferably, the valve block 610 housing 613 ismade of Radel R5000 from Piedmont Plastics, Inc. of Charlotte, N.C. andavailable from distributors throughout the United States, or othertranslucent plastic or glass material to provide superior chemicalresistance and clarity for operation and maintenance inspections. Thevalve block 610 housing 613 is preferably arranged and molded as anintegral piece as depicted. Other materials can be used for the valveblock 610 and related components, and the valve block 610 can be formedfrom one or more parts. Flanges 609 or other connectors can be joined toor molded integrally with the valve housing 613 to permit convenientmounting with snap-in features, screws, or other suitable fasteners.

The valve block housing 613 includes several pass-through inlets 614though which sanitizing fluids flow. Pass though inlets 614 are used sothat a number of valve blocks can be arranged in series and suppliedwith sanitizing fluids from a common source, if desired. Otherarrangements can be used, but arranging valve blocks in series requiresfewer hoses for sanitizing fluids and less demand on pumps and othersupply components. Flow through the pass through inlets 614 can be ineither direction to accommodate a variety of dairy layouts.

Most of the pass through inlets 614 communicate with a corresponding anddedicated block inlet 614 a that is controlled by its respective valveto permit entry of a predetermined fluid into a chamber 619 throughconduits 614 b. One exception is the pass through inlet 614 for thesecond air valve 612, which communicates with the lower bell portion 625of the axial chamber 619 at a position under the spool 621 via passages635 a and 635 b so that pressurized air can force the spool 621 into thesanitizing position (FIG. 21D), when desired.

The valve block 610 can include any number of valves corresponding tothe number of sanitizing fluids used. In the illustrated embodimentthere are five valves, depicted in FIG. 22A including: a first air valve611 that provides air to push liquids from the liner 49 and somewhat drythe teat; a second air valve 612 that moves a valve block safety spool621 into place and can provide air pressure to push sanitizing liquidssuch as sanitizers and water toward the liner 49 onto a teat; a thirdair valve 620 provides air for slugging sanitizing fluids and forcomplete surface rinsing and vigorous scrubbing of the dairy animalteat; a water valve 622 that provides water to be used to rinse theliner 49 and teat; and a sanitizer solution valve 624 that provides oneor more chemical solutions for sanitizing teats.

All valves are preferably solenoid valves, including the third air valve620, which is preferably a pilot operated valve that ensures air flowfor backflush slugging. Also preferably, the sanitizer solution valve624 is made of stainless steel or other material that resists corrosionfrom the sanitizer fluids. For ease of reference, each valve is joinedto the valve block 610 at a seat and each seat is designated in FIGS.21B and 21C with a numeral matching its respective valve and includingthe suffix “a”, so that valve 620 is mounted on seat 620 a, for example.

The first air valve 611 is reserved for only operating the safety valve60 to help ensure complete, independent, and safe operation of thesafety valve 610. Independent operation of some valves may be desirableto avoid pressure fluctuations that could result in from sharing airsupply pressure with other system components. The air from air valve 611exits the safety valve block 610 through a separate outlet 615 for thisreason. The first air valve 611 could be separate from the safety valveblock 610 and mounted elsewhere in the system because it does not usethe common outlet 637. Nonetheless, the safety valve block 610 providesa convenient mounting location and helps keep all of the hoses for thepass through inlets 614 organized. The second air valve 612 supplies airto the teat cup 48 and liner 49.

The spool 621 (FIGS. 21C and 21D) includes an upper valve head 626 and alower valve head 628. The upper valve head 626 and the lower valve head628 each define an annular groove in which seals 626 a and 628 a aredisposed, respectively. The seals 626 a and 628 a are preferably u-cupseals oriented as depicted to provide a sealing function in onedirection each. U-cup seals provide satisfactory sealing properties andreduce friction between the seals and the central housing 613 so thatthe spool 621 moves relatively easily with a relatively low airpressure.

The seals 626 a and 628 a oppose each other to seal the axial chamber619 at their respective ends. This seal orientation can permit fluid topass into the axial chamber 619. The spool 621 can be made of anysuitable material such as stainless steel, stable plastic, or othermaterial. The seals 626 a and 628 a can be made of Viton (FKM) or anyrubber, silicone or other suitable material or the seals can be formedintegrally with the spool 621.

A valve block spring 630 biases the spool 621 toward the milkingposition (FIG. 21C). The valve block spring 630 engages a seat 631 onthe upper valve head 626 and is contained within cap 633. An alignmentrod 639 extending from the upper valve head 626 of the spool 621 fits insocket 641 (FIG. 21C) formed in a cap 633 to maintain proper alignmentof the spool 621 when moving between the milking position (FIG. 21C) andthe backflushing position (FIG. 21D).

In the milking position (FIG. 21C), the spool 621 is forced by the valveblock spring 630 to engage the upper valve head seal 626 a with thewalls of the axial chamber 619 to seal the common outlet 637 from thechamber 619 with an end seal 627. The lower valve head 628 is forceddown into the lower bell portion 625 and does not engage the walls ofthe axial chamber 619, but the lower valve head 628 includes a recess629 that fits around and seals the air outlet 617 while permittingdrainage of residual fluids through drain 634. In the milking position,there is a space between the spool 621 and the walls of the axialchamber 619 that extends between most of the length of the axial chamber619. The drain (or vent) 634 is in communication with the axial chamber619 to “bleed” any differential pressure between the valves and the milkline thereby minimizing migration of dips and backflush fluids into themilk lines. The drain 634 is preferably located near the bottom of theaxial chamber 619 to provide a drain for any fluids in the axial chamber619 when the spool 621 is in the milking position.

The valve block 610 can be controlled by a stall control or othercontrollers to move to the sanitizing position for dairy animalpreparation. In the sanitizing position (FIG. 21D), the spool 621 isforced (upward as illustrated) against the bias of the valve blockspring 630 by pressurized air entering the inlet 635 to move the lowervalve head 628 into sealing engagement with the walls of the axialchamber 619 to seal the vent 634 and open the air outlet 617. In thesanitizing position, the upper valve head 628 does not seal anythingbecause it is disposed in the upper bell portion 623, and opens theaxial chamber 619 to the common outlet 637.

The inlets for the air valve 620, the water valve 622, and thesanitizing fluid valve 624 all communicate with the axial chamber 619through inlets 614 a, so that all of these fluids can flow through theaxial chamber 619 and out of common outlet 637 when their respectivevalves are opened and the spool 621 is in the sanitizing position. Thefluids do not typically flow together, instead the various valves firein a predetermined sequence to supply sanitizing fluids at the specifictime needed by the safety valve 610, as described below. All hoseconnections to the valve block 610 can be made with any suitableconnection, including a John Guest fitting, as depicted in outlet 617.

In the present invention there are various process options. Severalexamples are in Chart B below.

CHART B Process option Cycle 1 Cycle 2 Cycle 3 1 Sanitizer (2 liters)none Air 2 Water (2 liters) Sanitizer (1 liter) Air 3 Water + surfactantSanitizer (.5 liters) Air (2 liters)

Sanitizer options are available from GEA Farm Technologies, Inc., of1880 Country Farm Drive, Naperville, Ill. 60563 and include:

-   -   BiSept—0.35% (2.9% lactic acid, 0.7% sodium chlorite)    -   Oxycide—1% hydrogen peroxide    -   Dermasept—1% Capric-caprylic acid    -   Theraderm—0.25% available iodine    -   Theratec—0.5% iodine

Fifteen seconds is a preferred minimum contact time for any sanitizer,but other contact times are possible depending on a particular dairyanimal, ambient conditions or the type of sanitizer used.

Generally, once sanitizer and/or water is applied, filtered oil-free airis admitted into the liner through the same inlet using valve 118. Thisair flow continues until the teat is dry and residue is removed from themilk tube.

When milking is completed and the teat cups have been removed, the teatcup assembly returns to a cleaning station where all cups arebackflushed into the waste line.

All fluids entering the waste line are carried away from the milking boxand discarded to drain. This circuit is washed during the clean-in-placeprocess in a similar fashion as the good milk circuit is washed two tothree times per day. Additional washings will be performed followingextended idle periods.

The present invention ensures that sanitizer fluids and dirt cannot flowinto the milk line system, despite differential pressures in the milklines and preparation system. As stated above, to prevent seepage pastvalves and seals, the present invention includes a type of valvearrangement described above as “block-bleed-block.” Standard valves andseals can fail or allow seepage due to differential pressure on oppositesides of seals used in milk, teat dip, and backflushing lines. Theblock-bleed-block function of the invention prevents migration ofsanitizer through valves and seals into the milk lines by supplying apair of spaced apart valves and a vent or “bleed” to atmosphere, withthe vent being disposed between two seals. Multiple block-bleed-blockarrangements are used in the invention to provide redundancy and safetyboth upstream and downstream from the teat cup 48 and liner 49.

In the present invention, there is preferably the valve block 610 joinsair, water, and sanitizer supply lines and channels them to a commonvalve block outlet for efficiency. The valve block 610 also provides apressure bleeding vent between a pair of seals to further protect milklines from contamination.

In the milking position (FIG. 21C), the spool 621 is forced by the valveblock spring 630 to engage the upper valve head seal 626 a with thewalls of the axial chamber 619 to seal the common outlet 637 from thechamber 619 with an end seal 627. The lower valve head 628 is forceddown into the lower bell portion 625 and does not engage the walls ofthe axial chamber 619, but the lower valve head 628 includes a recess629 that fits around and seals the air outlet 617 while permittingdrainage of residual fluids through drain 634. In the milking position,there is a space between the spool 621 and the walls of the axialchamber 619 that extends between most of the length of the axial chamber619. The drain (or vent) 634 is in communication with the axial chamber619 to “bleed” any differential pressure between the valves and the milkline thereby minimizing migration of sanitizing fluids into the milklines. The drain 634 is preferably located near the bottom of the axialchamber 619 to provide a drain for any fluids in the axial chamber 619when the spool 621 is in the milking position.

Effectiveness of an automated preparation system is recorded in thecharts depicted in FIGS. 22A-B, respectively.

The foregoing detailed description of the invention is for clearness ofunderstanding the present invention, and no unnecessary limitationstherefrom should be read into the following claims.

The invention claimed is:
 1. A dairy system safety valve comprising: afirst single-seat valve having: a body defining, a first openingdefining a first valve seat, and a second opening; and a first plungerhead for movement between an open position that is spaced apart from thefirst valve seat, and a closed position that is engaged with the firstvalve seat; a second single-seat valve having: a body defining, a firstopening in communication with a vent and defining a second valve seat,and a second opening in fluid communication with the second opening ofthe first single-seat valve, and a third opening; and a second plungerhead for movement between an open position that is spaced apart from thesecond valve seat to open the vent, and a closed position that isengaged with the second valve seat to block the vent; and a thirdsingle-seat valve having: a body defining, a first opening defining athird valve seat, and a second opening in fluid communication with thethird opening of the second single-seat valve; and a third plunger headfor movement between an open position that is spaced apart from thethird valve seat, and a closed position that is engaged with the thirdvalve seat.
 2. The dairy system safety valve of claim 1, wherein thefirst plunger head and the third plunger head move substantiallysimultaneously between their respective open positions and closedpositions.
 3. The dairy system safety valve of claim 1, wherein thefirst plunger head and the third plunger head move substantiallysimultaneously between their respective open positions and closedpositions, so that when in the open positions, the first opening of thefirst single-seat safety valve is in fluid communication with the firstopening of the third single-seat valve.
 4. The dairy system safety valveof claim 1, wherein the dairy system safety valve is in ablock-bleed-block position when the first plunger head is in the closedposition, the second plunger head is in the open position, and the thirdplunger head is in the closed position.
 5. The dairy system safety valveof claim 1, wherein the dairy system safety valve is in an open positionwhen the first plunger head is in the open position, the second plungerhead is in the closed position, and the third plunger head is in theopen position.
 6. The dairy system safety valve of claim 1, and furthercomprising: a position sensor for generating a first signalcorresponding to the position of the plunger head of at least one singleseat valve.
 7. The dairy system safety valve of claim 1, and furthercomprising: an air activator for moving the plunger head of at least onesingle-seat valve between the open position and the closed position. 8.The dairy system safety valve of claim 1, wherein the first single-seatvalve and the third single-seat valve are interchangeable.
 9. The dairysystem safety valve of claim 1, wherein the first single-seat valve issubstantially identical to the third single-seat valve.
 10. The safetyvalve of claim 1, wherein the second opening of at least one of thesingle-seat valves is in fluid communication with the third opening ofthat single-seat valve when its plunger head is engaging the valve seat.11. The safety valve of claim 1, wherein at least one of the single-seatvalves further comprises: a wall permanently blocking the secondopening.
 12. The safety valve of claim 1, wherein at least one of thesingle-seat valves further comprises: a wall permanently blocking thethird opening.
 13. A dairy system safety valve comprising: a pluralityof single-seat valves in fluid communication with each other, and eachsingle-seat valve includes: a body defining a first opening, a secondopening and a third opening, and the first opening defines a valve seat;and a plunger head for movement between a closed position engaged withthe valve seat, and an open position spaced apart from the valve seat.14. The dairy system safety valve of claim 13, wherein the plurality ofsingle-seat valves comprises a first single-seat valve, a secondsingle-seat valve, and a third single-seat valve, and the firstsingle-seat valve plunger head and the third single-seat valve plungerhead move substantially simultaneously between the open position and theclosed position.
 15. The dairy system safety valve of claim 14, whereinthe first single-seat valve plunger head and the third single-seat valveplunger head move substantially simultaneously between the open positionand the closed position, so that when in the open position, the firstopening of the first single-seat safety valve is in fluid communicationwith the first opening of the third single-seat safety valve.
 16. Thedairy system safety valve of claim 14, wherein the dairy system safetyvalve is in a block-bleed-block position when the plunger head of thefirst single-seat valve is in the closed position, the plunger head ofthe second single-seat valve is in the open position, and the plungerhead of the third single-seat safety valve is in the closed position.17. The dairy system safety valve of claim 14, wherein the dairy systemsafety valve is in an open position when the plunger head of the firstsingle-seat valve is in the open position, the plunger head of thesecond single-seat valve is in the closed position, and the plunger headof the third single-seat safety valve is in the open position.
 18. Thedairy system safety valve of claim 14, wherein the first single-seatvalve and the third single-seat valve are interchangeable.
 19. The dairysystem safety valve of claim 14, wherein the first single-seat valve issubstantially identical to the third single-seat valve.
 20. The dairysystem safety valve of claim 13, and further comprising: a positionsensor for generating a first signal corresponding to the position ofthe plunger head of at least one single seat valve.
 21. The dairy systemsafety valve of claim 13, and further comprising: an air activator formoving the plunger head of at least one single-seat valve between theopen position and the closed position.